EP3819333A1 - Perles de mousse, pièce moulée formée d'une pluralité de perles de mousse et procédé de fabrication de perles de mousse - Google Patents

Perles de mousse, pièce moulée formée d'une pluralité de perles de mousse et procédé de fabrication de perles de mousse Download PDF

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Publication number
EP3819333A1
EP3819333A1 EP19207585.1A EP19207585A EP3819333A1 EP 3819333 A1 EP3819333 A1 EP 3819333A1 EP 19207585 A EP19207585 A EP 19207585A EP 3819333 A1 EP3819333 A1 EP 3819333A1
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EP
European Patent Office
Prior art keywords
plastic
foam
core
pet
beads
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EP19207585.1A
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German (de)
English (en)
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EP3819333B1 (fr
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Rouven Seitner
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Individual
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Individual
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Priority to EP19207585.1A priority Critical patent/EP3819333B1/fr
Priority to US17/775,208 priority patent/US20220347896A1/en
Priority to PCT/EP2020/080844 priority patent/WO2021089566A1/fr
Publication of EP3819333A1 publication Critical patent/EP3819333A1/fr
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/16—Making expandable particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/3461—Making or treating expandable particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B9/00—Making granules
    • B29B9/02—Making granules by dividing preformed material
    • B29B9/06—Making granules by dividing preformed material in the form of filamentary material, e.g. combined with extrusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
    • B29C44/22—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/36—Feeding the material to be shaped
    • B29C44/46—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length
    • B29C44/50—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length using pressure difference, e.g. by extrusion or by spraying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/36—Feeding the material to be shaped
    • B29C44/46—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length
    • B29C44/50—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length using pressure difference, e.g. by extrusion or by spraying
    • B29C44/507—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length using pressure difference, e.g. by extrusion or by spraying extruding the compound through an annular die
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/04—Particle-shaped
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
    • B29C48/21—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/345—Extrusion nozzles comprising two or more adjacently arranged ports, for simultaneously extruding multiple strands, e.g. for pelletising
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/22—After-treatment of expandable particles; Forming foamed products
    • C08J9/224—Surface treatment
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/22—After-treatment of expandable particles; Forming foamed products
    • C08J9/228—Forming foamed products
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00—Thermal insulation in general
    • F16L59/02—Shape or form of insulating materials, with or without coverings integral with the insulating materials
    • F16L59/029—Shape or form of insulating materials, with or without coverings integral with the insulating materials layered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B29K2067/003—PET, i.e. poylethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/772—Articles characterised by their shape and not otherwise provided for
    • B29L2031/7734—Spherical
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2201/00—Foams characterised by the foaming process
    • C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
    • C08J2201/03—Extrusion of the foamable blend
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2367/00—Characterised by the use of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Derivatives of such polymers
    • C08J2367/02—Polyesters derived from dicarboxylic acids and dihydroxy compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2423/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2423/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • C08J2423/10—Homopolymers or copolymers of propene
    • C08J2423/12—Polypropene

Definitions

  • the invention relates to foam beads, in particular for the production of molded parts, and a molded part formed from a multiplicity of foam beads. It also relates to a method for making such foam beads.
  • Foam beads or spheres made of foamed plastic are used in a large number of applications, for example for the production of molded parts, the molded parts being formed from a large number of such foam beads sintered or welded together. They offer a particularly good basis for a generally desired lightweight construction, since on the one hand they have a comparatively high mechanical stability and on the other hand - due to the high proportion of air in the material as a result of the foaming - have a very low density.
  • Such beads or foam beads are usually made from various types of polymer as the base material.
  • EPS, EPP, EPE, copolymers and mixtures thereof (blends) are available as beads.
  • foam beads are usually processed further in automatic molding machines to form molded parts, panels or blocks that can be used in the insulation, automotive or packaging industries or in other technical applications.
  • EPS beads rigid foam
  • EPP expanded polypropylene
  • EPS beads rigid foam
  • end processors in particular so-called foaming companies
  • foaming companies with the help of steam to form foam balls of different densities and then processed in the molding machines.
  • EPP flexible foam
  • minipellets made of polypropylene are already expanded to the appropriate density intended for later use at the raw material supplier, for example in an autoclave or by means of an extrusion process with direct gassing.
  • the resulting foamed balls or foam beads no longer contain any further propellant and can be processed directly using the dynamic pressure method.
  • the beads can be recharged with air pressure (pressure increase in the foam cells) and also expanded with steam.
  • the subsequent processing in the so-called molding process usually takes place in special molding machines.
  • the actual processing step consists in at least superficially softening the foam particles by means of steam (steam temperature approx. 140 to 165 ° C - depending on the type of raw material) so that they sinter or fuse.
  • Subsequent processing e.g. deburring
  • EPP molded parts unlike PUR foam parts.
  • the focus is usually on individually different material properties that make their use particularly attractive.
  • the flexible shape in combination with - due to the high proportion of air in the foamed beads - good thermal insulation properties is important.
  • the focus is usually on the generally desired lightweight construction in combination with the generally desired high level of passive safety, the low density in combination with a comparatively high level of shock absorption.
  • Another application spectrum is offered by the EPP foam, which is comparatively elastic, shockproof and particularly pleasant to the touch.
  • the range of applications is essentially limited by the material properties of the plastic used for the foam beads themselves, since they are above them For example, both the strength and dimensional stability of the molded part (via the strength and stability of the sintered or welded connection between the foam beads) and the thermal and mechanical properties of the solid (via the volume or weight proportion of air content or plastic proportion in the foamed bead) are given.
  • the general aim is to expand the number of possible applications even more than before and, in view of the large number of positive properties of such foam beads, to expand their possible uses even more than before.
  • the invention is now based on the object of specifying a foam bead of the above-mentioned type which, especially after processing into a corresponding molded part, is also suitable for novel, hitherto unknown applications. Furthermore, a molded part produced from such foam beads and a method for producing such foam beads are to be specified.
  • the foam bead has a core formed by a first plastic and a shell that at least partially surrounds the core and is formed by a second plastic, the second plastic forming the shell having a lower melting point than that of the core forming first plastic.
  • the invention is based on the consideration that the range of applications for molded parts formed from sintered or welded foam beads is essentially characterized by two aspects of the foam beads: on the one hand, there are the volume properties of the respective foam beads, i.e. the material properties of the plastic used in combination with the proportion of air , decisive, for example, for the density (and thus ultimately the weight of the molded part), thermal conductivity of the molded part or the like. On the other hand, the surface properties of the foam bead determine the strength of the sintered or welded composite and thus the mechanical strength and resilience of the molded part as a whole. Possible applications and the usability of specific materials are limited, among other things, by that in conventional construction the plastic used must meet both the requirements for volume properties and the requirements for surface properties, i.e. the strength of the sintered connection or the usability in conventional process technology.
  • this is taken into account by a structure of the foam beads, which allows a material-related or functional separation or decoupling of the volume on the one hand and the surface on the other.
  • a core for the foam bead which is characteristic of the volume properties, but which should be at least partially surrounded by a jacket made of a different material in the manner of a hybrid or two-component design. This can be suitably selected with regard to the production and / or strength of the desired sintered connection between the beads, without this having to accept restrictions for the choice of material for the core.
  • the melting point is regarded as a particularly important material property when selecting the materials for the core on the one hand and the jacket on the other hand, since this is important for the jacket in view of the intended sintering process.
  • the melting temperature is the temperature at which a substance melts, i.e. changes from a solid to a liquid state.
  • the melting temperature is usually dependent on the substance, but in contrast to the boiling temperature only very little on the pressure (melting pressure). Melting temperature and pressure are referred to together as the melting point, which describes the state of a pure substance and is part of the melting curve in the phase diagram of the substance.
  • the melting point of the second plastic forming the jacket is at least about 60 ° C., preferably at least about 90 °, lower at an ambient pressure of about 1 to 5 bar, in particular in the steam atmosphere usually provided for further processing is than the melting point of the first plastic forming the core. Due to the spread of the material parameters, a reliable sintering or welding of the foam beads is made possible, especially with process parameters such as temperature and pressure (for example the process steam used) that are common in system processes, even if the plastic used for the core, for example, which characterizes the bulk or volume properties Due to a comparatively high melting point, it would actually not be usable or processable under such conditions.
  • process parameters such as temperature and pressure (for example the process steam used) that are common in system processes, even if the plastic used for the core, for example, which characterizes the bulk or volume properties Due to a comparatively high melting point, it would actually not be usable or processable under such conditions.
  • the first plastic forming the core is a polyester, particularly preferably based on polyethylene terephthalate (PET).
  • PET is particularly suitable for recycling processes, which is why, in addition to PET produced for the first time, recycled PET can also be used to manufacture a variety of products. Products made from PET play an important role in the market, and PET is preferred particularly in the beverage and packaging industries where lightweight bottles and packaging films are required.
  • PET bottles and PET foils are shredded and the resulting granules are used to manufacture new bottles, sheets or foils.
  • the recycled material can also be used to manufacture other plastic parts, for example PET in the form of foamed sheets.
  • PET Compared to similar, foamable plastics from which molded parts can be produced using beads, PET also has a better thermal insulation effect on the one hand and, in the foamed state, on the other hand a significantly higher compressive strength compared to EPP or EPS, for example in the production of insulating bodies or the like, the use of PET would be particularly attractive.
  • the use of PET as a base material in foam beads is therefore already highly attractive in and of itself.
  • a method for producing a PET granulate is, for example, from WO 2011/063806 A1 known.
  • PET has a melting point of 260 ° C.
  • a use in the current system technology in the production of molded parts from foam beads or Beads is therefore not possible, or at least not commercially feasible, because in the current system technology used in the production of molded parts (for example for EPP foam beads), temperatures in the range from 120 ° C. to 150 ° C. are predominantly used.
  • the beads are usually welded together with the aid of steam; typical vapor pressures are around 3.6 bar. Treatment of PET foam beads will cause expansion at such temperatures, but not weld. Rather, a weld would require temperatures above 200 ° C, which would result in steam pressures of 20 bar and more.
  • the second plastic forming the jacket is a plastic based on polypropylene (PP).
  • PP polypropylene
  • PP has a melting point of about 160 ° C, EPP, on the other hand, of about 140 ° C, so that the sintering or welding of the PP or EPP-encased PET foam beads, which are particularly preferred and which are considered to be independently inventive, with the usually provided and plant-related also largely converted temperatures of 120 ° C to 150 ° C can take place.
  • the difference in melting points between the particularly preferred material pairings with PET for the core and PP or EPP for the jacket is thus around 100-125 K (for PET-PP) or 120-145 K (for PET-EPP).
  • the shell of the foam bead surrounding the core has the essential functional task of enabling the sintering or welding of the foam beads to one another under common system conditions and process parameters and thereby ensuring adequate dimensional stability and mechanical strength of the sintered body.
  • the jacket does not completely surround or cover the core; Rather, it may be sufficient to provide the surface with a jacket only to the extent that in any case, even with a statistical positioning of a large number of foam beads relative to one another, a sufficient material-side connection of foam beads that are adjacent to one another is guaranteed.
  • the jacket thus advantageously covers at least 70% of the surface of the core.
  • the layer thickness of the jacket is suitably selected, also with a view to the intended functional task of the jacket, namely that it should enable the foam beads to be sintered or welded together.
  • the layer thickness of the jacket it should be particularly preferred that it has a sufficient material thickness to enable an intensive and resilient material connection between neighboring foam beads, whereby on the other hand the volume contribution of the jacket should be kept sufficiently low, see above that the volume properties are dominated or determined unchanged by the material of the core.
  • the jacket has a layer thickness of 0.1 to 0.5 mm.
  • the foam beads which are provided in the form of an intermediate product for subsequent processing, can be temporarily stored using existing systems and, if necessary, loaded with ambient air under pressure.
  • the foamed cylindrical granulate can then or at a later point in time be further processed with conventional EPP system technology.
  • the existing steam pressure and machine technology is sufficient to expand the PET foam and at the same time to obtain a well-welded particle foam block due to the welding in the PP casing.
  • the stated object is achieved in that it is formed from a multiplicity of superficially sintered or welded foam beads of the aforementioned type.
  • a multiplicity of foamed plastic bodies formed from a first plastic is integrated into one formed from a second plastic Matrix embedded.
  • the foam beads are connected to one another by welding the jacket layers to one another;
  • the jacket layers preferably form a matrix in which the original cores of the foam beads are embedded as separate plastic bodies.
  • the second plastic forming the matrix has a lower melting point, preferably at least about 60 ° C., particularly preferably at least about 90 °, lower melting point than that of the plastic body at an ambient pressure of about 1 bar forming first plastic.
  • foam beads defined above and / or the molded part described above are particularly preferred and used as an insulation material for sanitary, heating or ventilation technology (hot water pipe insulation, boilers, cast parts), insulation material for automobile construction (sound and heat-insulating parts), and in an embodiment that is regarded as independently inventive such as engine compartment partitions, Wheel arches), crash protection for automobile construction (bumpers), and / or crash protection for protective equipment (helmets, knee pads).
  • the stated object is achieved according to the invention by mixing a melt of a first plastic, particularly preferably PET, with a blowing agent or blowing agent mixture and optionally additives and making it available for a subsequent extrusion, the extrusion in a coextrusion takes place in which the foamed first plastic emerging from a perforated nozzle expands and is encased by a second plastic, particularly preferably PP, emerging from an annular nozzle at least partially surrounding the perforated nozzle, the resulting plastic being covered by a film made from the second plastic Sheathed strand of the first plastic is cut into cylinders after cooling.
  • a first plastic particularly preferably PET
  • a blowing agent or blowing agent mixture and optionally additives optionally additives
  • a plastic film made of polypropylene that encases the PET strand is applied in the form of a tube around the resulting strand of foamed PET. Due to the comparatively high process temperature when the PET strand emerges from the perforated nozzle, the PP casing is firmly welded to the foamed PET strand, so that an intimate, cohesive connection between the foamed PET forming the core and the PP forming the casing is preferred arises. After cooling, the coextruded strands are advantageously cut into cylinders, which form the foam beads, in the manner of a so-called cold cut.
  • the second plastic used is a plastic that has a lower melting point than the first plastic.
  • the stated object is achieved with regard to the method by mixing a melt of a first plastic, advantageously PET, with a propellant or propellant mixture and optionally additives are mixed and then extruded and expanded in the process, the resulting plastic-foam strand being passed in a sheathing step through a treatment basin in which a second plastic, preferably polypropylene, is provided in a highly viscous form.
  • a first plastic advantageously PET
  • a propellant or propellant mixture and optionally additives are mixed and then extruded and expanded in the process, the resulting plastic-foam strand being passed in a sheathing step through a treatment basin in which a second plastic, preferably polypropylene, is provided in a highly viscous form.
  • the process parameters are advantageously selected in such a way that when the foamed PET strand is passed through the PP bath, a PP coating is deposited on the surface of the PET strand and, due to the comparatively high temperatures, is firmly welded to it becomes.
  • the strand made of foamed plastic is led out of the treatment basin in a substantially vertical direction, so that excess residual amounts still on the surface of the strand due to gravity run back into the treatment basin and are available there for further coating.
  • the stated object is achieved with regard to the method by mixing a melt of a first plastic, advantageously PET, with a blowing agent or blowing agent mixture and optionally additives, the polymer melt loaded with the blowing agent in a sheathing step is passed through a flow channel in which a melt of a second plastic is provided and the polymer melt loaded with the blowing agent flows around, the encased melt then being extruded and expanded in the process.
  • a melt of a first plastic advantageously PET
  • a blowing agent or blowing agent mixture and optionally additives optionally additives
  • the two-component design of the foam bead enables a functional separation between the core on the one hand and the jacket forming the surface on the other hand, so that the core is specifically designed in terms of its execution, for example material selection, air content and the like can be adapted to the volume-related requirements.
  • the jacket can be tailored to the surface-specific requirements, in particular good sintering behavior and / or high strength can be adapted after the sintering or welding of the foam beads without having to accept disadvantages in the volume range.
  • the structure according to the invention enables the inclusion of new materials, very particularly preferably PET, while maintaining the established and already existing system technology for further processing.
  • the foam pearl 1 according to. Fig. 1 also referred to as a sphere made of foamed plastic or also as a "bead", is used for a large number of applications, for example for the production of a molded part 2, as shown in FIG Fig. 2 shown, suitable and intended.
  • a molded part 2 As shown in FIG Fig. 2 shown, suitable and intended.
  • these are sintered or welded to one another.
  • the foam bead 1 is specifically designed for an extended range of applications, in which - if possible with recourse to existing plant and process technologies - also new types of materials that were previously not usable for these purposes for various reasons are to be made available for possible use.
  • the foam bead 1 is designed as a hybrid design with two or more components; it comprises a core 4 formed from a first plastic and in addition to this a jacket 6 which at least partially surrounds the core 4 and is made from a second plastic.
  • This two-component or multi-component design allows the core 4 to be independent of the jacket 6 with regard to the choice of material and other properties be executed. In the present case, this is used to also be able to use PET as a base material for the provision of foam beads 1.
  • the core 4 of the foam bead 1 is thus made from a polyester in the exemplary embodiment, namely PET in the present case.
  • PET has a melting point of around 260 ° C., so that further processing by sintering or welding to produce a molded part 2 using current system technology would not be possible.
  • working temperatures of about 120 ° C to 150 ° C are usually used; this would not be sufficient to bring about the sintering of the PET foam beads necessary for the production of a molded part 2 from PET beads.
  • the PET core 4 in the foam bead 1 is surrounded by the jacket 6 made of the second plastic.
  • the material is selected such that the second plastic forming the jacket 6 has a significantly lower melting point than the first plastic forming the core 4.
  • polypropylene (PP) is provided as the material for the jacket 6; the foam bead 1 is thus a PP-coated PET bead.
  • Polypropylene has a melting point of around 160 ° C and thus a significantly lower melting point than PET.
  • the two-component structure of the foam bead 1 thus ensures that the volume properties (for example elasticity, thermal conductivity, etc.) are shaped by the material forming the core 4, i.e.
  • the foam bead 1 is thus a foam bead 1, which consists essentially of PET, but can be treated during further processing and sintering in the framework conditions and appropriate system technology, as is available and already established for EPP beads.
  • the molded part 2 obtainable by sintering or welding a multiplicity of foam beads 1 is shown in FIG Fig. 2 shown.
  • the predominantly cohesive connection of adjacent foam beads 1 to one another takes place via the respective jacket 6, the cores 4 being retained.
  • the molded part 2 thus takes after its production in Fig. 2 Matrix structure shown in section, in which a plurality of the original cores 4 corresponding, from the first plastic, namely, in the present case PET, foamed plastic bodies 10 formed is embedded in a matrix 12 formed by the second plastic, namely in the present case PP.
  • the matrix 12 is created by fusing, sintering or welding the jackets 6 of the foam beads 1 to one another.
  • foam beads 1 of the embodiment shown is possible in several ways, of which two are explained in more detail below, only by way of example, each considered to be independently inventive.
  • the two exemplary embodiments listed have in common that they are based on the extrusion of continuous strands with subsequent separation by cold cutting, turning away from the water granulation processes actually customary in the production of foam beads or beads.
  • the following embodiments are explained by way of example with reference to the particularly preferred material pairing, which is regarded as independently inventive, of PET as the first plastic for forming the cores 4 and polypropylene (PP) as the second plastic for forming the casing 6;
  • PET the particularly preferred material pairing
  • PP polypropylene
  • a PET melt is first mixed with a blowing agent or blowing agent mixture and optionally additives and then fed to a coextrusion.
  • the expanded PET foam strand 20 Immediately after its exit from the perforated nozzle 20, the expanded PET foam strand 20 'still has a comparatively high process temperature. As a result, the PP film 28 is firmly welded to the foamed PET strand 20 'during the sheathing. This creates an intimate cohesive connection between the foamed PET forming the core 4 and the PP forming the jacket 6.
  • the coextruded strands i.e. the PP-coated PET foam strands
  • the coextruded strands are separated in the manner of a cold cut and cut into cylinders. These then form the actual foam beads 1, in which a PP jacket 6 surrounds the foamed PET core 4.
  • FIGS Figs. 4th and 5 The concept of an alternative method for producing the foam beads 1 is shown schematically in two embodiments in FIGS Figs. 4th and 5 shown.
  • a PET melt is also initially mixed with a blowing agent or blowing agent mixture and, if appropriate, additives.
  • the resulting mixture 30 is then extruded in a nozzle 32 and expanded in the process.
  • the resulting PET foam strand 34 is then passed through a treatment basin 36 in a sheathing step.
  • Polypropylene (PP) is provided as the second plastic in the treatment basin 36.
  • the treatment basin 36 is heated and suitably tempered by means of a heating device not shown, so that the PP in the treatment basin 36 is in the liquid state in a highly viscous form.
  • the process parameters are selected in such a way that when the PET foam strand 34 is passed through the PP bath, a PP sheathing 38 is deposited on the surface of the PET foam strand 34. Due to the comparatively high temperatures of the PET foam strand 34 in this phase, the casing 38 is firmly welded to the PET foam strand 34 during the deposition. Subsequently, the PET foam strand 34 provided with the jacket 38 is passed through a water bath 40 for cooling and then separated in a separation station 42 in the manner of a cold cut and cut into cylinders. These then form the actual foam beads 1, in which a PP jacket 6 surrounds the foamed PET core 4.
  • the PET foam strand 34 provided with the sheathing 38 is guided out of the treatment basin 36 in an essentially vertical direction indicated by the arrow 44.
  • This aspect is particularly preferred and is considered to be inventive in its own right, because this alignment means that excess residual amounts of the jacket material (PP) still on the surface of the foam strand 34 are automatically conveyed back into the treatment basin 36 due to gravity, where they are available for further coating.
  • PP jacket material
  • FIG. 6 Some particularly preferred exemplary embodiments for the encased PET foam cylinders produced by one of the processes mentioned and forming the foam beads 1 are shown in FIG Fig. 6 , each shown in both a cross section and a longitudinal section.
  • the foam pearl 1 according to. Figure 6a has a length L of 3.0 mm and a core diameter of 3.0 mm; the jacket thickness d is 0.25 mm.
  • the foam bead 1 'according to FIG. Figure 6b a length L of 4.0 mm, a core diameter of 3.0 mm and a jacket thickness d of 0.1 mm and the foam pearl 1 "according to.
  • Figure 6c a length L of 4.0 mm, a core diameter of 2.0 mm and a jacket thickness d of 0.5 mm.
  • the geometry parameters of these particularly preferred exemplary embodiments are summarized in the following table:
  • Foam bead 1 Foam bead 1 ' Foam bead 1 " core diameter 3.0 mm 3.0 mm 2.0 mm length 3.0 mm 4.0 mm 4.0 mm
  • Coverage Proportion of the outer surface 66.7% 72.7% 80.0% Jacket thickness 0.25 mm 0.1 mm 0.5 mmm Ground core 2.1 mg 2.8 mg 1.3 mg Ground coat 0.7 mg 0.4 mg 1.3 mg Sheath / core mass ratio 33.3% 13.3% 100%
  • the PET foam cylinders with PP sheathing 38 which are produced with one of the two processes described above - or also some other - forming the foam beads 1 can then be temporarily stored and, if necessary, charged with ambient air under pressure, depending on the application.
  • the foamed cylindrical granulate can then be further processed later with normal, conventional EPP system technology.
  • the steam pressure and machine technology is particularly sufficient to expand the PET foam and at the same time to obtain a well-welded particle foam block or a well-welded molded part 2 due to the welding in the PP casing 38.
  • the construction of the foam beads 1 as a PP-coated PET bead allows, among other things, the following leeway for the subsequent application and thus expands the range of applications as a whole:
  • the foamed cylindrical raw material can also be produced in relatively high densities in the range 100-200 kg / m 3 as required.
  • the PET foam core 4 can be prefoamed in the prefoaming process at temperatures of approximately 120 ° C. without the PP sheathing 38 causing the foam beads 1 to weld.
  • the foam beads 1 can be temporarily stored like conventional EPS or EPP beads and optionally loaded with compressed air.
  • the foam beads 1 can be fed to conventional EPP molding systems and processed there, in particular foamed and welded with steam in the temperature range of about 150 ° C.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Polymers & Plastics (AREA)
  • Materials Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Organic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Molding Of Porous Articles (AREA)
EP19207585.1A 2019-11-07 2019-11-07 Perles de mousse, pièce moulée formée d'une pluralité de perles de mousse et procédé de fabrication de perles de mousse Active EP3819333B1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
EP19207585.1A EP3819333B1 (fr) 2019-11-07 2019-11-07 Perles de mousse, pièce moulée formée d'une pluralité de perles de mousse et procédé de fabrication de perles de mousse
US17/775,208 US20220347896A1 (en) 2019-11-07 2020-11-03 Foam bead, molded article formed of a plurality of foam beads, and method for producing foam beads
PCT/EP2020/080844 WO2021089566A1 (fr) 2019-11-07 2020-11-03 Bille expansée, moulage formé par une pluralité de billes expansées et procédé de production de billes expansées

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EP19207585.1A EP3819333B1 (fr) 2019-11-07 2019-11-07 Perles de mousse, pièce moulée formée d'une pluralité de perles de mousse et procédé de fabrication de perles de mousse

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TWI736254B (zh) * 2020-05-08 2021-08-11 國立臺北科技大學 複合材料層及其製造方法

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DE19728879A1 (de) * 1996-12-09 1998-06-10 Gefinex Gmbh Kunststoffschaum-Beads
DE102007033312A1 (de) * 2007-07-18 2009-01-22 Rudolf Ohlinger Gmbh & Co. Kg Verfahren zur Herstellung eines Flaschenverschlusses
EP2428532A2 (fr) * 2009-05-06 2012-03-14 Polma Co., Ltd. Particule de polystyrène expansé comportant une couche superficielle ayant une formabilité supérieure, procédé de production associé, et article moulé en polystyrène expansé l'utilisant
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EP3819333B1 (fr) 2023-02-22
WO2021089566A1 (fr) 2021-05-14

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